Oil Chip Detector Housing Design and Benchmarking for Aerospace Engines

Team Honeywell Jered Deal Ilenn Johnson Cullen Matillano John Selee Jacob Vedder Team Honeywell September 16, 2019; Honeywell 1

Project Description Figure 1. Honeywell logo [1] Design, analyze and prototype an oil chip detector housing. Client: Honeywell Knowing the quality of the oil without having to manually check Jacob Vedder September 16, 2019; Honeywell 2

Background Engine systems wear and release debris which oil chip detectors collect and notify users of. Commonly used on larger vehicles such as aircraft and helicopters. Installed in the oil line, perpendicular to the flow direction. Figure 2. Engine sensor and housing [2] Figure 3. Engine housing sensor [3] Figure 4. Engine sensor [4] Jacob Vedder September 16, 2019; Honeywell 3

Benchmarking Housings for on-line sensors aren't commercially available. In-line sensors are generally self-contained. Current benchmarking will include pros and cons of each design/model Modularity Universal fitments Maximum efficiencies Jacob Vedder September 16, 2019; Honeywell 4

Benchmarking -Allen Aircraft Products, Inc Figure 5. Complete in-line design by AAP with strainer attached; specifically for aircraft engines. [5] Ilenn Johnson September 16, 2019; Honeywell 5

Figure 6. An exploded CAD view of a Swiss-built Meggitt Sensor. Notable innovations include variable pulse outputs to differentiate between chip sizes as the oil flows through the center.[6] Benchmarking Meggitt Sensing Systems Ilenn Johnson September 16, 2019; Honeywell 6

Benchmarking - Eaton Figure 7. The Eaton Zapper System, a comprehensive kit from a reputable manufacturer intended for aircraft engines and transmissions. This model is designed for on-line use.[7] Ilenn Johnson September 16, 2019; Honeywell 7

Literature Review Wearing of on-line oil chip detector systems[8]-Ilenn Oil Debris Monitoring in Aerospace Engines and Helicopter Transmissions[9]-Jacob Signal Processing to Overcome Random Vibration Interference in an Oil Debris Monitor (ODM) sensor[10]- Cullen Experimental Investigation on the Influence of Engine Oil Additives on Silicone Rubber[11] - Jered In-line oil debris monitor for aircraft engine condition assessment[12] - John Jered Deal September 16, 2019; Honeywell 8

Characteristic Expectation Weight <1lb Customer Requirements Temperature Resistance 5 min at 2,000 F; 2 min at 310 F Operating Temperature -65 to 260 F Size Given Envelope, TBD dimensions Shock Resistance 6g operating, 20g crash Withstand Operating Oil Pressure TBD psig Altitudes -2,000 to +55,000 feet Table 1. Primary Customer Requirements Jered Deal September 16, 2019; Honeywell 9

Engineering Requirements Need Design Requirement Within Budget < $2000 Durable TBD Use Time, Reliable Works through changes in temperature, altitude, attitude Safe in Operation Holds operating pressure with FoS>TBD Appropriate Material Non-Reactive metals with melting point > 2000 F Table 2. Engineering Requirements Jered Deal September 16, 2019; Honeywell 10

Temperature Resistance; (5 min @ 2,000; 2min at 310) Operating Temperature -65 to 260 Oil Chip Detector Interface (0.75) Within Budget (1,000-2,000) Envelope Size (TBD) Burst Pressure (TBD) Vibration Resistance Customer Weights 10 10 10 8 10 9 9 8 8 10 10 10 Quality Assurance Safe in Operation Force Loads Weight (<1) Reliability Durability Design Objectives 1. Weight 2. Temperature Resistance 3. Fluid Flow 4. Flammability 5. Shock Resistance 6. Capture Frequency 7.Size 8. Operation Altitude 9. Operating Pressure 10. Leak Free 11. Load Supportive(Static and Dynamic) 12. Fuel and Oil Resistance Phase 1 3 9 9 9 9 9 9 9 9 9 9 1 3 9 9 9 9 1 9 3 3 9 3 3 9 9 9 9 3 1 1 1 9 9 9 3 9 9 9 9 9 9 1 3 3 1 9 9 9 9 3 9 9 3 3 9 3 9 9 3 9 3 9 9 9 9 9 9 9 9 9 3 1 House of Quality (HoQ) correlates Customer Needs to Engineering Requirements 9 3 9 9 3 9 Absolute Importance (ATI) Technical 331 657 498 468 190 262 221 405 351 306 240 264 765 0 0 0 0 Relative Importance (RTI) Unit of Measure Techical Target Technical Phase 1 includes ATI and RTI 13% 10% 15% 7% 9% 4% 5% 4% 8% in2 7% 6% 5% 5% 0% 0% 0% 0% rad/s2 $ *ul *ul *ul lbm in psig Hz *ul F F *ul--> Unitless by method Table 3. Phase 1 House of Quality (HoQ) Cullen Matillano September 16, 2019; Honeywell 11

Table 4. House of Quality Cullen Matillano September 16, 2019; Honeywell 12

Part Characteristics (1-10) Phase 2 Oil Chip Housing Exterior Phase I Relative Weights Straight Screw threads Fluid Inlets & Outlets Locking Features Threaded Inserts Oil Chip Sensor Correlates specifications to possible parts Determines the Relative Weight of each possible part Fasteners Specifications 7% 13% 10% 9% 4% 5% 4% 8% 7% 6% 5% 5% 15% 0% 0% 0% 0% 0 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 9 10 0 5 10 8 10 10 10 10 10 9 1 9 9 5 0 10 5 10 10 10 10 10 10 0 0 0 0 10 10 10 10 10 10 10 10 10 0 Within Budget Durability Reliability Safe in operation Weight Temperature Resistance; Operating Temperature Envelope Size Oil Chip Detection Interface Burst Pressure Force Loads Vibration Resistance Quality Assurance 10 10 10 0 0 0 0 10 0 0 0 0 10 10 10 0 0 0 0 10 0 0 0 10 5 5 8 5 6 9 8 8 10 10.0 4.0 8.7 8.1 7.8 8.5 5.5 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 Raw score 19% 16% 15% 15% 16% 10% 8% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% Relative Weight Table 5. Phase 2 HoQ Cullen Matillano September 16, 2019; Honeywell 13

Figure 6. Phase 2 HoQ Cullen Matillano September 16, 2019; Honeywell 14

Schedule Gantt Chart used to establish project tasks and Deadlines Currently ahead of schedule Prototype ready to test by February 2020 John Selee September 16, 2019; Honeywell 15

Honeywell Capstone Legend: Gantt Chart On Track Low Risk Med Risk High Risk Unassigned Honeywell Project Start Date: 9/8/2019 Scrolling Increment: 0 September October 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Milestone DescriptionCategory Assigned To Progress Start No. Days S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S Milestone Prelim Report Milestone Team 100% 9/11/2019 1 Customer Meeting Milestone Team 100% 9/12/2019 1 Requirements Milestone Team 100% 9/12/2019 2 House of Quality Presentation 1: CN's/ER's Design Space Research/ Lit On Track Team 75% 9/12/2019 4 On Track Individual 0% 9/14/2019 4 9/16/2019 1 Peer Eval 1 On Track Individual 0% 9/18/2019 7 Concept Generation On Track Team 0% 9/24/2019 4 Selected Design Presentation 2: Concept gen &Eval Preliminary Report Rough On Track Team 0% 9/24/2019 13 Low Risk Team 40% 9/28/2019 9 On Track Individual 0% 10/1/2019 20 Analysis Prelims Prelim. Report Checks Goal Honeywell 0% 10/7/2019 3 Milestone Team 0% 10/14/2019 0 Prelim. Report Due Table 7. Gantt Chart John Selee September 16, 2019; Honeywell 16

Budget Total budget: $1000-2000 Anticipated expenditures per device: Machining process: $200 Materials: $100 Machining can be done on NAU campus Prototypes can be tested with Honeywell 4 prototype models are expected to be made and 1 final model will be made Expected remaining budget: $500 John Selee September 16, 2019; Honeywell 17

Questions? Team Honeywell September 16, 2019; Honeywell 18

References [1] Honeywell, Honeywell. [Online]. Available: https://www.honeywell.com/. [Accessed: 10-Sep-2019]. [2] Australian Transport Safety Bureau, "Engine Failure Lake Burbury, Tasmania 5 February 2006," Australian Government, Canberra City, 2007. [3] I. Lad, "Mag Chip Detector," Isambardkingdom, 8 January 2012. [Online]. Available: http://isambardkingdom.com/?attachment_id=537. [Accessed 10 September 2019]. [4] K. V. Sagar, "Clogging Of Oil Filters, Oil Jets, Its Consequences and a requirement of pressure relief valve (PRV) in oil filters of jet engines," International Journal of Mechanical Engineering and Technology (IJMET), vol. 8, no. 6, pp. 156-166, 2017. [5] Chip Detectors, Allen Aircraft Products, Inc. [Online]. Available: http://www.allenaircraft.com/products/chip_detectors.html. [Accessed: 10-Sep-2019]. [6] Oil debris monitoring: MeggittSensing, Meggitt Sensing Systems, 10-May-2017. [Online]. Available: https://meggittsensing.com/aerospace/product/oil-debris-monitoring/. [Accessed: 10-Sep- 2019]. [7] Sensors and Limit Switches, Sensors and Limit Switches for Automation and Control Applications, 2019. [Online]. Available: https://www.eaton.com/ecm/groups/public/@pub/@eaton/@aero/documents/content/ct_194538.pdf . [Accessed: 10-Sep-2019]. [8]Z. Yunbo and G. Yuhai, "Research of the on-line system for detecting metal particles in oil," 2017 13th IEEE International Conference on Electronic Measurement & Instruments (ICEMI), Yangzhou, 2017, pp. 98-102. [9] S. Showalter, S. Pingalkar and S. Pasha, "Oil debris monitoring in aerospace engines and helicopter transmissions," 2012 1st International Symposium on Physics and Technology of Sensors (ISPTS-1), Pune, 2012, pp. 157-160. [10] W. Chen, "Signal Processing to Overcome Random Vibration Interference in an Oil Debris Monitor (ODM) Sensor." Order No. MR86285, University of Ottawa (Canada), Ann Arbor, 2012. [11]Kusuhara, S., Yoshimura, K., Kunieda, K., Suzuki, N., Matsuki, S. and Shitara, Y. (2017). Experimental Investigation on the Influence of Engine Oil Additives on Silicone Rubber. SAE International Journal of Fuel & Lubricants, [online] 10(2), pp.461-468. Available at: http://eds.b.ebscohost.com.libproxy.nau.edu/ehost/detail/detail?vid=0&sid=aa09a570-99af-47f4-9316- d7ad0840a8db%40sessionmgr103&bdata=JnNpdGU9ZWhvc3QtbGl2ZSZzY29wZT1zaXRl#AN=122441314&db=a9h [Accessed 13 Sep. 2019]. [12]J. Miller and D. Kitaljevich, In-line oil debris monitor for aircraft engine condition assessment, 2000 IEEE Aerospace Conference. Proceedings (Cat. No.00TH8484). John Selee September 16, 2019; Honeywell 19